Mat including a composite structure

ABSTRACT

A mat includes a first surface having a first polymer, a second surface having a second polymer, and indicia associated with a game. The first polymer can include, for example, an elastomer, such as a silicone elastomer. The second polymer can include, for example, a fluorinated polymer.

TECHNICAL FIELD

The invention relates to mats, such as gaming boards, and methods of making and using the same.

BACKGROUND

Many games are played on a mat. For example, in games such as Monopoly® and Risk®, play pieces are moved and dice are thrown on a rigid board. The board or mat can be unfolded for play and folded for storage. In other games, such as chess and Pente®, a flexible mat can be unrolled for play and rolled up for storage. Gaming mats can be made of, for example, crushed felt, cardboard, or plastic-coated fabric.

SUMMARY

In one aspect, the invention features gaming mats and games including the mats. A mat includes a first surface having a first polymer, a second surface having a second polymer, and indicia associated with a game. In some embodiments, the first polymer has a higher coefficient of friction than a coefficient of friction of the second polymer. The first polymer can include, for example, an elastomer, such as a silicone elastomer. The second polymer can include, for example, a fluorinated polymer.

In another aspect, the invention features a mat having a first surface including a silicone elastomer; a second surface including a fluorinated polymer; and indicia associated with a game.

In another aspect, the invention features a game including a mat having a first surface including a silicone elastomer, a second surface including a fluorinated polymer, and indicia associated with the game; and a playing piece associated with the game.

Embodiments of the aspects may include one or more of the following features. The indicia are between the first and second surfaces. The indicia contact the first surface and/or the second surface. The mat further includes fibrous reinforcement, e.g., one including fiberglass and polyaramid yarns and/or coated with the fluorinated polymer. The fibrous reinforcement is woven. The silicone elastomer is coupled to the fluorinated polymer. The fibrous reinforcement is coated with the silicone elastomer. The silicone elastomer has a higher coefficient of friction than that of the fluorinated polymer. The mat further includes a bonding agent, such as one including silica, contacting the second surface. The indicia include a regular pattern, e.g., hexagons, rectangles, or squares. The playing piece includes a die.

The mat can be included in a mouse pad, used as shelf covers, used as refrigerator hangings, and used as erasable boards (e.g., white boards). For example, use of a mat as a mouse can include contacting a computer mouse to a structure including the mat described herein and moving the mouse relative to the structure. A structure including a mat described herein can include an adhesive, and the structure can be applied to (e.g., adhered) to shelving and/or cabinetry. Use of a mat described herein can include placing a structure including the mat on a support (such as a refrigerator or a wall), and marking on the structure (e.g., the mat itself). Marks can be subsequently erased, and the structure can be re-marked. Variously sized structures (e.g., from approximately paper size (8.5 inch×11 inch) to 4 ft×8 ft) can be made and used.

As used herein, a “game” is an article (such as a merchandised article) that is used (e.g., played) for recreational, entertainment, amusement, and/or educational purposes. A game can include packaging (such as a box or a container), one or more play pieces (such as dice and playing pieces or markers), a mat or board on which the playing pieces are moved, and instructions for playing the game. The mat or board can be folded or rolled for storage in the packaging.

As used herein, “mat” and “board” are used interchangeably.

Other aspects and features will be apparent from the description of the embodiments thereof and from the claims.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a diagram illustrating an embodiment of a game.

FIG. 2 is a cross-sectional diagram of an embodiment of a mat.

FIG. 3 is a cross-sectional diagram of an embodiment of a mat.

DETAILED DESCRIPTION

FIG. 1 shows an embodiment of a game 20, such as Monopoly® and Risk®. As shown, game 20 includes packaging 22 (such as a box or a container for storing components of the game), a mat 24, one or more playing pieces 26 (such as dice, a spin wheel, and players' markers), and printed instructions 28 for playing the game. During use, mat 24 and playing pieces 26 are removed from packaging 22, and the playing pieces can be moved on the mat. After use, mat 24 can be folded or rolled and stored in packaging 22, along with playing pieces 26.

Referring also to FIG. 2, mat 24 is a composite structure including (e.g., is formed of) two or more layers. As shown, mat 24 includes two layers 30, 32 that form a first major surface 34 and an opposite second major surface 36, respectively, and indicia 38 (e.g., printed graphics) associated game 20. In some embodiments, first major surface 34 includes (e.g., is formed of) a high coefficient of friction material, such as a silicone elastomer, and second major surface 36 includes (e.g., is formed of) a material (such as a fluorinated polymer) having a low coefficient of friction (e.g., lower than the coefficient of friction of the first major surface). First major surface 34 can be placed face down on a surface (such as a table or a floor) and playing pieces 26 can be placed and moved on second major surface 36.

Layer 30 includes a high coefficient of friction material that can reduce slippage and help keep mat 24 in place on an intended surface. For example, layer 30 may include elastomeric material. Exemplary materials include polyorganosiloxane, polyolefins, polyurethane, ethylene propylene diene monomer (EPDM) polymers, and mixtures thereof. In some embodiments, the material included in layer 30 is substantially free of fluorination. In some embodiments, the material included in layer 30 also has low surface energy and may, for example, be non-stick material. For example, layer 30 may include polyorganosiloxane, such as silicone elastomer.

Layer 32 includes a low surface energy material, such as a non-stick and/or non-reactive material. In some embodiments, the material included in layer 32 has a low coefficient of friction. The material of layer 32 protects layer 30 and mat 24 from damage (e.g., from food and liquids), and allows the mat to be marked on (e.g., with a marker) and easily cleaned for reuse. For example, layer 32 may include fluorinated polymer. The fluorinated polymer can be a homopolymer of fluorine-substituted monomers or a copolymer including at least one fluorine-substituted monomer. Exemplary fluorine substituted monomers include tetrafluoroethylene (TFE), vinylidene fluoride (VF2), hexafluoropropylene (HFP), chlorotrifluoroethylene (CTFE), perfluoroethylvinyl ether (PEVE), perfluoromethylvinyl ether (PMVE), and perfluoropropylvinyl ether (PPVE). Examples of fluorinated polymers include polytetrafluoroethylene (PTFE), perfluoroalkylvinyl ether (PFA), fluorinated ethylene-propylene copolymer (FEP), ethylene tetrafluoroethylene copolymer (ETFE), polyvinylidene fluoride (PVDF), polychlorotrifluoroethylene (PCTFE), and TFE copolymers with VF2 and/or HFP. Layer 32 can include one material or a mixture of materials.

While layers 30, 32 are illustrated as a single layer each, the layers may be formed of several layers of their respective materials described above. For example, layer 30 may be formed through coating several layers of fluoropolymer and sintering after each coating or after the final coat is applied.

Other components may be present in the materials used to form layer 30 and/or layer 32. For example, one or more layers can include fillers, light stabilizers, pigments, and bonding aids. Exemplary fillers include talc, silica, and calcium carbonate. Exemplary light absorbing additives and pigments include TiO₂, Fe₂O₃, carbon black, and calcined mixed metal oxides. One or both layers 30, 32 can include one or more materials (e.g., an ink) that allow the layer(s) to be thermally addressable or laser addressable to form indicia. Examples of addressable materials are described, for example, in U.S. Pat. No. 6,835,424.

In some embodiments, a mat includes reinforcement, such as fibrous reinforcement. FIG. 3 illustrates a mat 40 including reinforcement 42. As shown, layer 44 includes a low surface energy material and form a major surface 48. Layer 46 includes a high coefficient of friction material and form a major surface 50. Layer 44 may include materials described above for layer 30 of FIG. 2, and layer 46 may include materials described above for layer 32 of FIG. 2. As show, reinforcement 42 is incorporated into layer 44. Alternatively or additionally, reinforcement 42 is incorporated into layer 46. In some embodiments, reinforcement 42 is located between layers 44, 46.

Reinforcement 42 can include (e.g., be formed of) organic and/or inorganic materials. Exemplary inorganic materials include carbon fiber, metal filament, such as steel and copper wire, ceramic filaments, such as glass fiber, and blends thereof. Exemplary organic materials include natural fibers, such as cotton, wool, and blends thereof and polymeric materials, such as polyester, polyamide, polyaramid, polyamideimide, polyimide, polyolefin, and blends or copolymers thereof. In some embodiments, reinforcement 42 is incorporated into layer 44 and is formed from polyaramid materials, such as meta- or para-polyaramid materials. In some embodiments, reinforcement 42 is incorporated into layer 46 and is formed from polyester materials or polyamide material, such as nylon materials. Reinforcement 42 can be coated with one or both of the materials in layers 44, 46, for example, coated so as to be substantially embedded in one or both of the layers. For example, reinforcement 42 may be coated with fluorinated polymer (e.g., embedded in layer 44) or may be (coated with silicone elastomer (e.g., embedded in layer 46).

Reinforcement 42 can include woven fibers (e.g., stitched or in a weave) and/or non-woven fibers, (e.g., randomly distributed fibers). A mat can include one or more layers, sheets or types of reinforcement material.

In some embodiments, a mat is formed through a process of coating a carrier web and/or a reinforcement with a low surface energy, low coefficient of friction material, such as fluorinated polymer, e.g., PTFE. Prior to coating, selected indicia associated with the game can be applied to the carrier web and/or the reinforcement. After the coating process, the low surface energy, low coefficient of friction material can serve as a protective layer for the indicia. The indicia can be in the form of graphics, letters, words, numbers, symbols, etc. For example, for the game Risk®, the indicia may include graphics showing a map, and for the game Monopoly®, the indicia may include areas showing the various properties. The indicia can be applied using inkjet marking (e.g., printing), screen marking (e.g., printing), laser marking, and/or by hand (e.g., writing with a marker). Alternatively or additionally to applying indicia on the carrier web (e.g., by rotary screen printing) and/or the reinforcement, indicia can be applied on the low surface energy, low coefficient of friction material. The indicia on the low surface energy, low coefficient of friction material can be different from or the same as the indicia applied on the carrier web and/or the reinforcement (e.g., overlaid).

The carrier web and/or the reinforcement are paid from a roll and coated on one side with a suspension including fluorinated polymer particles dispersed in a liquid medium. For example, the suspension can include Fluon® ADILN PTFE aqueous dispersion to which 0.5% Zonyl® FSO fluorosurfactant from DuPont has been added. A blade or metering rods are positioned to remove excess suspension from the carrier web. The suspension is then dried and sintered to form a layer on the carrier web. In some embodiments, the coated suspension is dried at about 332° F. and sintered at about 649° F. The thickness of the layer may be increased by repeating the coating process. In other embodiments, the carrier web may be coated with the suspension, the suspension dried, and a second coating applied to the dried suspension before sintering.

An exposed surface of the fluorinated polymer can be rendered bondable or more bondable. For example, the surface may be chemically etched with an etching composition, such as sodium metal/naphthalene/glycol ether mixture and sodium metal/anhydrous ammonia mixture. In other embodiments, the surface is rendered bondable through electrochemical treatments, metal sputtering and deposition of metals and/or metal oxides. For example, deposition of metals and metal oxides may include chemical vapor deposition and physical vapor deposition.

In other embodiments, the surface of the fluorinated polymer is rendered bondable or more bondable by impregnating the material with colloidal silica. For example, the fluorinated polymer may include 25-70 wt % colloidal silica. In a further example, the surface may be rendered bondable by applying to the surface a coating of FEP or PFA including colloidal silica. The FEP or PFA coating is dried and sintered or fused to the surface of the fluorinated polymer, such as PTFE. In other embodiments, the fluorinated polymer surface is coated with a mixture of DuPont FEP TE-9503, Ludox® LS 30 colloidal silica dispersion from W.R. Grace Company, and Triton® X-100 non-ionic surfactant.

Once the surface is bondable or more bondable, a high coefficient of friction material, such as silicone elastomer, is applied to the bondable surface. For example, precursors of silicone elastomer may be coated on the bondable surface and cured. In some embodiments, a platinum catalyzed liquid silicone rubber solution is applied to the bondable surface of the fluorinated polymer layer. The coating may be heated to deactivate or evaporate inhibitors, allowing the liquid silicone rubber solution to cure. In other embodiments, an organic peroxide catalyzed silicone rubber is coated to the fluorinated polymer layer and the coating is heated to facilitate curing. Other exemplary silicone elastomers include moisture-curing silicones. In embodiments, the silicone elastomer precursor coating includes 50 parts 9252-500P Part A and 50 parts 9252-500P Part B liquid silicone rubber from Dow Corning Corporation in which Part A includes a platinum catalyst and Part B includes a crosslinking agent and a cure inhibitor capable of being removed by heat. Multiple coatings of the silicone material may be applied, and reinforcement may be incorporated in the silicone layer.

In exemplary embodiments, the thickness of the fluorinated polymer layer is generally about 0.2-12 mils. In one example, the thickness is about 4-12 mils. In another example the thickness is about 0.2-4 mils, such as about 0.5-4 mils. The silicone layer is generally about 2-100 mils. In one example, the thickness of the silicone layer is about 4-20 mils. Alternatively, the thickness of the silicone layer is about 2-10 mils, such as about 5-10 mils. For example, when a reinforcement is embedded in the fluorinated polymer layer, the thickness of the fluorinated polymer layer may be about 4-12 mils and the thickness of the silicone layer may be about 2-10 mils. Alternatively, when the reinforcement material is embedded in the silicone layer, the thickness of the fluorinated polymer layer may be about 0.5-4 mils and the thickness of the silicone layer may be about 4-20 mils.

Further details of the construction of a mat can be found in, for example, US Patent Application Publication No. US 2001/0034170A1, incorporated herein by reference.

While a number of embodiments have been described, the invention is not so limited.

For example, while embodiments of mats are described above as associated with games, in other embodiments, the mats are separately packaged. For example, a mat can include indicia of a grid or a regular array of shapes, such as hexagons, rectangles, squares, and circles. The mat can be used with various games (such as Dungeons & Dragons®, and strategy games) where players may want to map certain areas and/or to show positions and movements of character pieces. The mat allows the players to write and to draw on the mat, and to easily remove (e.g., with a solvent or water) the markings for re-use.

The mats can be made flexible so that they can be rolled for storage, or the mats can be made stiff and scored so that they can be folded for storage.

The mats can be used for other applications. For example, a mat can be included in a mouse pad, used as shelf covers, used as refrigerator hangings, and used as erasable boards (e.g., white boards).

All references, such as patents, patent applications, and publications, referred to above are incorporated by reference in their entirety.

Other embodiments are within the scope of the following claims. 

1. A mat, comprising: a first surface comprising a silicone elastomer; a second surface comprising a fluorinated polymer; and indicia associated with a game.
 2. The mat of claim 1, wherein the indicia are between the first and second surfaces.
 3. The mat of claim 1, wherein the indicia contact the first surface.
 4. The mat of claim 1, wherein the indicia contact the second surface.
 5. The mat of claim 1, further comprising fibrous reinforcement.
 6. The mat of claim 5, wherein the fibrous reinforcement is woven.
 7. The mat of claim 6, wherein the fibrous reinforcement comprises fiberglass and polyaramid yarns.
 8. The mat of claim 6, wherein the fibrous reinforcement is coated with the fluorinated polymer.
 9. The mat of claim 8, wherein the silicone elastomer is coupled to the fluorinated polymer.
 10. The mat of claim 5, wherein the fibrous reinforcement is coated with the silicone elastomer.
 11. The mat of claim 1, wherein the silicone elastomer has a higher coefficient of friction than that of the fluorinated polymer.
 12. The mat of claim 1, further comprising a bonding agent contacting the second surface.
 13. The mat of claim 12, wherein the bonding agent comprises silica.
 14. The mat of claim 1, wherein the indicia comprises a regular pattern.
 15. The mat of claim 14, wherein the pattern comprises hexagons, rectangles, or squares.
 16. A game, comprising: a mat comprising a first surface comprising a silicone elastomer, a second surface comprising a fluorinated polymer, and indicia associated with the game; and a playing piece associated with the game.
 17. The game of claim 16, wherein the indicia are between the first and second surfaces.
 18. The game of claim 16, wherein the indicia contact the first surface.
 19. The game of claim 16, wherein the indicia contacts the second surface.
 20. The game of claim 16, further comprising fibrous reinforcement.
 21. The game of claim 20, wherein the fibrous reinforcement is woven.
 22. The game of claim 21, wherein the fibrous reinforcement comprises fiberglass and polyaramid yarns.
 23. The game of claim 21, wherein the fibrous reinforcement is coated with the fluorinated polymer.
 24. The game of claim 23, wherein the silicone elastomer is coupled to the fluorinated polymer.
 25. The game of claim 20, wherein the fibrous reinforcement is coated with the silicone elastomer.
 26. The game of claim 16, wherein the silicone elastomer has a higher coefficient of friction than that of the fluorinated polymer.
 27. The game of claim 16, further comprising a bonding agent contacting the second surface.
 28. The game of claim 27, wherein the bonding agent comprises silica.
 29. The game of claim 16, wherein the indicia comprise a regular pattern.
 30. The game of claim 16, wherein the pattern comprises hexagons, rectangles, or squares.
 31. The game of claim 16, wherein the playing piece comprises a die. 